Web processing apparatus and electric control therefor

ABSTRACT

Web processing apparatus for embossing, perforating and cutting off radiator fin segments of predetermined length from a continuous web of thin flexible metal includes web feed rolls, a rotary embossing and perforating die, and a cut-off knife, intermittently operable by a single-revolution solenoid operated cut-off clutch, for cutting off fin segments of precise length, with each fin segment comprising the same number of embossments and perforations. The feed rolls and the rotary die are driven in synchronism by a common motor. The cut-off clutch, also driven in synchronism by the common motor, operates in response to control means, which include a photoelectric sensing device responsive to rotation of said rotary die to provide electric pulses (indicative of the number of embossments or perforations) to a presettable electric counter. The counter effects a single operation of the cut-off clutch and knife each time a predetermined number of pulses are registered by the counter to thereby provide segments of predetermined length. Means are provided to enable an adjustment in the physical (phase) relationship between the photoelectric sensing device and the rotary die to enable the cut-off point to be adjusted so that each fin segment is cut at an appropriate place with respect to the embossments and perforations at the end of a fin segment.

United States Patent 1 Freres 1 1 Nov. 25, 1975 1 1 WEB PROCESSING APPARATUS AND ELECTRIC CONTROL THEREFOR [75] Inventor. Donald E. Freres, Racine. Wis.

[73] Assignee: Sterling Tool Company, Racine,

Wis.

Filed: Jan. 2, 1975 21 App1.No.:538,035

[52] US. Cl 72/185; 113/1 C; 83/298 [51] Int. Cl. BZID 55/04 [58] Field of Search 113/1 C; 72/185; 83/298. 83/321, 334, 335

[56] References Cited UNITED STATES PATENTS 2,876,723 3/1959 Lawrence 113/1 3.628.410 12/1971 Shields 83/335 3.742.798 7/1973 Gries 83/298 3.803.962 4/1974 Koslow v 1 1 83/335 3.814.145 6/1974 Gott ct 211., 140/112 3.839.974 10/1974 Frcrcs 113/1 Primary Examiner-Lowell A. Larson Atmrnev. Agent. or Firm.lames E. Nilles [57] ABSTRACT Web processing apparatus for embossing, perforating and cutting off radiator tin segments of predetermined length from a continuous web of thin flexible metal includes web feed rolls. a rotary embossing and perforating die. and a cut-off knife. intermittently operable by a single-revolution solenoid operated cut-off clutch, for cutting off fin segments of precise length. with each fin segment comprising the same number of embossments and perforations. The feed rolls and the rotary die are driven in synchronism by a common motor. The cut-off clutch, also driven in synchronism by the common motor, operates in response to control means, which include a photoelectric sensing device responsive to rotation of said rotary die to provide electric pulses (indicative of the number of embossments or perforations) to a presettable electric counter. The counter effects a single operation of the cut-off clutch and knife each time a predetermined number of pulses are registered by the counter to thereby provide segments of predetermined length. Means are provided to enable an adjustment in the physical (phase) relationship between the photoelectric sensing device and the rotary die to enable the cut-off point to be adjusted so that each fin segment is cut at an appropriate place with respect to the embossments and perforations at the end of a tin segment.

10 Claims, 10 Drawing Figures TVE ow om US. Patent Nov. 25, 1975 Sheet2of5 3,921,428

US. Patent N0v.25, 1975 Sheet30f5 3,921,428

US. Patent N0v.25, 1975 Sheet40f5 3,921,428

U.S. Patent Nov.25, 1975 SheetSofS 3,921,428

02 03 D1 DISPLAY DISPLAY PS sw c3 COUNTER cofi.

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WEB PROCESSING APPARATUS AND ELECTRIC CONTROL THEREFOR BACKGROUND OF THE INVENTION 1. Field of Use This invention relates generally to web processing apparatus and electric control means therefor. In particular it relates to apparatus for forming perforated embossed sheet metal fin segments of predetermined length from a continuously moving web of sheet metal, such fin segments being usable, for example, as component parts in radiator cores. Furthermore, in particular, the control means therefor senses the number of perforations and embossments being fonned and effects cutoff of a fin segment of a predetermined length when a predetermined number of perforations and embossments have been formed.

2. Description of the Prior Art Various types of apparatus of the aforesaid general character are known in the prior art. US. Pat. No. 3,650,233 discloses apparatus wherein a rotary embossing and perforating die and a fin cut-off knife are driven in synchronism and a change in fin segment length is accomplished by substituting different sized gears in the drive train when the machine is stopped. US. Pat. No. 3,839,974 discloses apparatus wherein the embossing die and the cut-off knife are driven by separate motors and the cut-off knife motor is controlled by an electronic control adjustable while the machine is in operation to change the length of the fin segments being cut off.

SUMMARY OF THE INVENTION In accordance with the present invention, there is provided web processing apparatus for embossing, perforating and cutting off radiator fin segments of predetermined length from a continuous web of thin flexible metal. The apparatus includes web feed rolls, a rotary embossing and perforating die, and a cut-off knife, intermittently operable by a single-revolution solenoid operated cut-off clutch, for cutting of fin segments of precise length, with each fin segment comprising the same number of embossments and perforations. The feed rolls and the rotary die are driven in synchronism by a common motor. The cut-off clutch, also driven in synchronism by the common motor, operates in response to control means, which include a photoelectric sensing device responsive to rotation of said rotary die to provide electric pulses (indicative of the number of embossments or perforations) to a presettable adjustable electric counter. The counter actuates the clutch solenoid to effect a single operation of the cut-off clutch and knife each time a predetermined number of pulses are registered by the counter to thereby provide segments of predetermined length. The sensing device comprises a perforated rotatable shaft-mounted disc disposed between a light source and a photocell, which disc is rotated by a first gear mounted on the disc shaft. The first gear meshes with and is driven by a second gear mounted on and driven by the rotary die. The sensing device is adjustably mounted in fixed position on or with respect to the support frame for the rotary die. Means are provided to enable an adjustment in the physical (phase) relationship between first gear of the photoelectric sensing device and the second gear of the rotary die to enable the fin segment cut-off point to be adjusted so that each fin segment is cut at an appropri- 2 ate place with respect to the embossments and perforations at the end of a fin segment.

Web processing apparatus and control means therefor in accordance with the invention offers several advantages over the prior art. For example, since the apparatus is intended to employ several rotary dies of different sizes, the phase adjustment means enable easy readjustment of the proper cut-off point after one rotary die is replaced with another. Furthermore. all op erative components in the apparatus are driven by a single motor in synchronized relationship. The sensing means is directly coupled mechanically to the embossing die and gives a sure indication of the embossing and perforating operations performed thereby when a web is being processed. The photoelectric sensing means employed is so constructed, located and operated that it is not subjected to false counts or faulty operation possibly caused by waste material or debris from interrupting the light beam, as is the case in some apparatus. The solenoid operated, single revolution counter-controlled cut-off clutch ensures positive cutting action while enabling easy changes in fin segment length and easy exact adjustment of the cut-off point. The apparatus and control are relatively economical to fabricate, employ commercially available components in the control means, are relatively simple to adjust and use, and are dependable in operation.

Other objects and advantages will hereinafter appear.

DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevational view of the fin forming apparatus made in accordance with the present invention, the view being taken from the operators side of the apparatus;

FIG. 2 is a schematic, perspective view of the drive for the various components of the machine taken from the opposite side of the machine;

FIG. 3 is a top plan view of the cut-off knife portion of the machine, the view being taken generally from above the apparatus;

FIG. 4 is a view partly in section taken generally along the line 44 in FIG. 3;

FIG. 5 is an end elevation view of the mechanism shown in FIG. 3;

FIG. 6 is a sectional view taken generally along the line 66 in FIG. 5;

FIG. 7 is an elevation view taken along the line 77 in FIG. 3; and

FIG. 8 is an electronic diagram showing the sensing device and counter used with the present invention.

FIG. 4a and 6a illustrate an alternative embodiment of the cut-off mechanism.

DESCRIPTION OF A PREFERRED EMBODIMENT Web Supply Means The apparatus provided by the present invention includes a supply roll stand 1 (FIG. 1) on which is rotatably mounted the supply roll SR for supplying a web W of copper or other material that is to be formed, for example, into fins for a heat exchanger, or the like. As the web is fed from the supply roll, a supply roll brake SRB is applied from time to time so as to prevent rotation of the supply roll, that is to say, the brake SRB is either on or off", the brake being on when the machine is stopped, as will more fully appear. The brake is of the air operated type, being actuated by a conventional air operated solenoid AOS4 (FIG. 2) which may be of the type manufactured by the Skinner Electric Valve Company of New Britain, Connecticut. In any event, the web of material is fed from the supply roll and forms a downwardly hanging loop L1 which is used up and then again formed as the machine operates.

Web Feed Means The web is fed, that is pulled from the supply roll SR. by a pair of feed rolls FR and FR2, the roll FR being driven through a feed roll clutch FRC and forming a feeding nip with the idler feed roll FRZ. The rolls are suitably journalled in conventional anti-friction bearing assemblies (not shown) in the frame 10. The feed roll clutch FRC is of conventional air operated type, such as made by the Horton Mfg. Co. of Minneapolis, Minnesota, being operated by an air operated solenoid AOS3 which is also of the above referred to Skinner" type. More specifically. the solenoid AOS3 actuates a conventional shiftable spool type air valve which directs air pressure from an air conduit to be directed to the clutch from a source of pressurized air.

Electric Eye An electric eye comprising a light source 5 and a receiving unit 6 is located on the downstream side of the feed roll FR and adjacent the lower portion of the web loop L and is understood to be electrically connected to the feed roll clutch FRC. An electric eye timer is also provided in the electric circuit. The operation generally is such that the clutch FRC stops, and consequently stops the web feed, for a period of time until the subsequent portion of the apparatus uses up the downwardly hanging loop L of web. As will more fully appear, the length of time during which the machine stops is adjustable by a potentiometer, that is to say, a condenser throwsthe switch of the timer to actuate the clutch. More specifically, the electric eye has two components; a sending unit 5 and a receiving unit 6 (FIGS. 1 and 2) located on opposite sides of the hanging web loop L. Thus. the feed rolls for the web are alternately driven or stopped to either use up the loop L of web or permit the formation of a new loop. Driving power is furnished to the clutch FRC of the feed roll FR from an endless timing belt 7 (FIG. 2), as will more fully appear.

Rotary Die Means Mounted in the main frame 10 of the machine is a rotatably driven rotary die RD which acts on the web W to perforate and otherwise form the web into the desired shape. The rotary die RD acts in cooperation with the rotatable rotary die anvil RDA, between which the web W passes. The rotary die and anvil may be of conventional form, and die RD is rotatably driven from a toothed, endless timing belt 12, to be referred to later, and which is trained around the timing sprocket l3 fixed on the shaft 14 of the die RD. The rotary die RD and the rotary die anvil RDA have projections and in-' dentations which complement one another in the known manner and these may be of various sizes and shape so that each can produce the desired pattern of slots, holes, or flanges on the finished fin, in the known manner. An example of such a general rotary die is shown for example in the US. Pat. No. 2,876,723 issued Mar. 10, 1959 to Lawrence. The die and anvil have constant mesh gears 13a and 13b, respectively, so that the anvil is precisely driven in timed relationship with the rotary die. Both the rotary die and anvil are 4 journalled in anti-friction bearings BR located in the frame 10 ofthe machine.

As the formed-web W leaves the rotary die, it passes to a cut-off knife means which will now be described.

Cut-Off Knife Means As clearly shown in FIGS. 1, 2, 3, 5 and 6, the cut-off knife means is adapted to handle the high speed web and precisely and cleanly cut the web into precise lengths without buckling, bending or otherwise distorting the web material which is often very thin. As the knife rotates at high speed and is frequently stopped and started, as it will later appear, it is important that the inertia and momentum problems be held at a minimum.

The knife assembly includes a bar 15 which is circular in cross section with a boss KB for holding the knife k, as shown in FIG. 6, and which is journalled in antifriction bearings 15a in the frame of the machine. The assembly also includes the knife k formed of hardened steel and recessed in the bar 15 and rigidly held therein by cap bolts 15b. The knife has a sharp edge along its length which cooperates with the rotatable knife anvil KA also journalled in anti-friction bearings 15c in the frame as shown in FIG. 5. Rotation of bar 15 and knife anvil KA is synchronized by constant mesh gears 40 and 41, respectively. By causing the knife anvil to rotate rather than being fixed or stationary, buckling or damage to the rapidly moving thin web is prevented.

As FIGS. 2, 3, 5 and 6 show, the knife bar 15 has a shaft 42 extending therefrom which extends through a solenoid operated knife clutch KC. A fly wheel assembly 42a to which weights can be added or subtracted is provided to provide proper inertia. Each time the clutch solenoid RS is energized, the clutch which has a portion which is continuously driven by a timing belt 39 from motor MM, as hereinafter explained, is engaged to effect one rotation of the knife bar 15 and one cutting operation of the knife K on the web. Clutch KC and its operating solenoid RS are commercially available as a clutch-brake package for starting and stopping a load driven from a continuously rotating source of power. The knife clutch KC comprises a clutchbrake having a stop collar 43 and a mounting plate 49 which adapts the clutch for mounting on frame 10. The clutch KC comprises a clutch input hub 44 which is continuously rotatable and is driven by a timing pulley 45 (driven by timing belt 39). As FIG. 5 best shows, the timing pulley 45 is directly connected both to the gear 40 by bolts 46 and to the input hub 44 of the clutch KC by dowel pin 46a. The pulley 45 and the gear 40 are mounted for relative rotation with respect to shaft 42 by means of ball bearing assemblies 48. As FIG. 4 shows, the stop collar 43 is provided with a shoulder or abutment 50 which is adapted for engagement by a pivotally mounted clutch operating lever 52. The lever 52 which is connected to the solenoid plunger by a pin 53a is biased by a spring 52a and is pivotally movable about a pin 53 on the mounting plate 49 and is operated by the clutch solenoid RS which is also mounted on the plate 49. The clutch KC also comprises a brake hub portion 54 which is rigidly secured by means of bolts 55 to frame 10. The clutch also comprises a brake spring 56 mounted internally thereof and a clutch spring 57 also mounted internally thereof. During operation of clutch KC input hub 44 is free to turn at all times, being driven by belt 39 and pulley 45. Gear 40 is continuously rotating and is continuously driving gear 41 and knife anvil KA. When the solenoid RS is energized by a pulse from the counter 19, as hereinafter explained, the stop collar 43 of clutch KC is released as lever 52 is moved out of engagement with shoulder 50 thereof and this allows clutch spring 57 to wrap down on the output hub 58 and the shaft 42, thus driving the knife bar 15. When the solenoid RS is de-energized, the lever 52 reengages shoulder 50 after one revolution of the stop collar. When rotation of the stop collar 43 is thus stopped it causes the clutch springs 57 to open thereby disconnecting the output hub from the drive inside of clutch KC. Simultaneously, the stop collar also engages the brake springs 56, wrapping them down on the output hub 58 and on the brake hub 54, thereby preventing clutch overrun due to load inertia. A clutch KC and its associated solenoid RS are commercially available as a preassembled industrial clutch brake package from PSI Division, Warner Electric Brake & Clutch Com pany, Delsa Drive, P. O. Box 118, Pitman, New Jersey 0807 l, and is described in that companys Bulletin A-l6 of September, 1970.

Adjustable Fin Measuring Means As hereinbefore explained, the web processing apparatus operates to emboss, perforate and cut off fin segments FF of predetermined length from the continuous web W of thin flexible metal. The web feed rolls FR and FR2, the rotary embossing and perforating die RD and its anvil RDA, and the cut-off knife bar and its anvil KA. Bar 15 is intermittently operable by the singlerevolution solenoid operated cut-off clutch KC, cuts off fin segments FF of precise length, with each fin segment comprising the same number of embossments and perforations. The feed rolls and the rotary die are continuously driven in synchronism by the common main electric motor MM. The cut-off clutch KC, also driven in synchronism by the motor MM, operates in response to control means, which include its solenoid RS and a photoelectric sensing device or shaft encoder PCU responsive to rotation of the rotary die RD to provide square wave electric pulses (indicative of the distance of angular rotation of die RD and thus the number of embossments or perforations impressed on web W) to a presettable adjustable electric counter 19. The counter 19 intermittently actuates the clutch solenoid RS to effect a single operation (one revolution) of the cut-off clutch KC and knife K each time a predetermined (preset) number of pulses are registered by the counter 19 to thereby provide fin segments FF of predetermined length. As FIG. 8 shows, the sensing device or shaft encoder PCU comprises a perforated rotatable disc DC disposed within the housing 60 of encoder PCU and mounted on the encoder shaft 61. The disc is disposed between a light source LS and a photocell PC in housing 60 and is rotated by a first gear 62 mounted on the shaft 61 outside of housing 60. Such a sensing device or shaft encoder PCU may be a High Speed Shaft Encoder Model 39300 manufactured by Durant Digital Instruments, a Cutler-Hammer Company, 901 South 12th, Street, Watertown, Wisconsin and described in their Bulletin CU-l37. Such a shaft encoder converts shaft rotation into sqaure wave output pulses to provide an accurate means of digitizing position or rate of rotation, with a wide range of output pulses per revolution (i.e., 1 to 1000 PPR) being available. The first gear 62 meshes with and is driven by a second gear 63 mounted on and driven by the stub shaft 64 extending from the end of the rotary die RD. The sensing de- 6 vice PCU is adjustably mounted on adjustable bracket or support means in fixed position on or with respect to the support frame 10 of the rotary die RD.

Means are provided to enable an adjustment in the physical (phase) relationship between first gear 62 of the shaft encoder PCU and the second gear 63 of the rotary die RD to enable the tin segment cut-off point to be adjusted so that each fin segment FF is cut at an appropriate place with respect to the predetermined num-' ber of embossments and perforations provided at the end of a fin segment FF. Thus, as FIGS. 3 and 7 show, the housing 60 of shaft encoder PCU is connected by two screws 65 to a plate 66 which is rigidly secured (welded) to and extends outwardly from an attachment plate 67 which is adjustably secured by means of a pair of adjustment screws 68 and a releasable holding screw 64 to an adjustable pivot plate 70. As FIG. 7 shows, the adjustment screws 68 can be inserted through either of three sets of holes 68a, 68b or 680 in plate 67 and plate 67 can be temporarily held in position with respect to frame 10 by means of holding screw 64 so that the sets of holes 68a, 68b or 68c can be brought into registry with one of the appropriate four sets of screw holes 67a, 67b, 670 or 67d in plate 70. By this means, the gear 62 on sensing unit PCU can be located at the proper distance from the rotational axis of rotary die RD to accommodate gears 63 of different diameter which are understood to be associated with dies RD of different diameter. Preferably, the plate 67 and 70 carry indicia (not shown) designating which sets of holes need to be brought into registry for dies of different diameter. Plate 70 is provided with a large opening 79 which adapts it for pivotal mounting on a bushing having a sleeve bearing 750 on the stub shaft 64 of rotary die RD, the bushing 75 being held on stub shaft 64 by means of a nut 73. Bushing 75 is secured to frame 10 by screws 76. A washer and keeper screw 70a hold plate 70 on bushing 75. Plate 70 is adjustably pivotable to desired positions for proper phasing of the gears 62 and 63 by means of a rotatable phase adjustment screw 77 on a bracket 78 which is secured to frame 10. A biasing spring 80 secured between a pin 81 on frame 10 and a screw 82 on plate 70 biases the plate 70 against the end of screw 77.

Since the apparatus is intended to employ several rotary dies RD and anvils RDA of different sizes, the phase adjustment means, including the screws 68 and 77, enable easy readjustment of the proper cut-off point after one rotary die RD is replaced with another of different circumference and having a different sized gear 63. The sensing means or shaft encoder PCU is directly coupled mechanically to the rotary die RD and gives a sure indication of the number of embossing and perforating operations performed thereby when web W is being processed. The sensing means PCU employed is so constructed, located and operated that it is not subjected to false counts or faulty operation possibly Fin Moving Means As the finished fins FF are discharged from the knife K, they leave the table 18 and enter into a guideway GW (FIG. 1) where their movement is accelerated by 7 jets of air issuing from spaced apart air tubes ATI and AT2 located above the path of the finished fins FF as they move along the guideway GW. The air blasts from the air tubes ATl and AT2 act on the fins to propel and accelerate them along the guideway GW and into the stacker and against stop 20a shown at the right hand side of FIG. 1.

Drive Means The power for driving the rotary die RD, the knife K and the feed roll FR is obtained from the electric main motor MM (FIG. 2) which is connected to a variable speed sheave VS, which can infinitely vary the output speed of the motor MM. The variable speed sheave VS is of the conventional type in which the opposite sheave halves are spring loaded together, such as shown in the U.S. Pat. No. 2,475,954 issued July, 12, 1949. Power is then transmitted from the sheave through a conventional endless belt 22 to a gear reducer GR which may be of the type manufactured by the Boston Gear Works Division of North Quincy, Massachusetts and shown, for example, in the U.S. Pat. No. 2,813,435 issued Nov. 29-, 1957 or in'U.S. Pat. No. 2,868,031 issued Jan. 13, 1959. The power is transmitted from the output shaft 24 of the gear reducer GR, through timing pulley 25 on shaft 24, and the endless timing belt 26 which is trained around pulley 25. A disc type brake MB for the main drive includes a large steel disc 28 on shaft 24 and on opposite sides of which are the air operated brakes 29 that are actuated by their air operated solenoids A051 and their associated air valves.

The gear reducer shaft 24 is also connected to a conventional air operated clutch AOC2 and its associated air valve, which may also be of the type manufactured by the Horton Mfg. Co., Inc. of St. Paul, Minnesota. The arrangement is such that either the main brake MB or the main clutch AOC2 are selectively operative. Power is furnished to the rotary die RD, to the knife K and to the feed roller FR by being transmitted from the endless timing belt 26 through pulley 26a and suitable toothed timing pulleys 12a and 33a fixed on the shaft 32, and respectively to the timing belt 12, and an end less timing belt 33 through suitable timing pulleys 34 and 35 fixed to another shaft 37 mounted on the main frame 10, and to endless timing belt 7. Knife bar 15 is driven through knife clutch KC by means of a timing belt 39 which is trained around pulley 45 and a pulley 45A driven by pulley 12a, as FIGS. 2, 3 and 5 show.

The air operated solenoids AOSl for the main brake, the air operated solenoids AOS2 which operate the air operated clutch AOC2, the air operated solenoid AOS3 which operates the feed roll clutch FRC and the air operated solenoid AOS4 which operates the supply roll brake SRB may all be of the type manufactured by the previously mentioned Skinner Electric Valve Company of New Britain, Connecticut and are of conventional character.

Electronic Circuit Broadly considered, as FIGS. 2 and 8 show, the electronic control circuit for operating knife K in synchronism with the rotary die RD comprises a source of elecric power P, the counter 19, the sensing device in the form of shaft encoder PCU for supplying input signals to counter 19, and the clutch solenoid RS for receiving output signals from counter 19.

Counter 19 is a commercially available device such as a Ser. 2000 Electronic Control available from the 8 Durant Digital Instruments Company, hereinbefore identified, and described in their Manual No. 29557- 7008.

Generally considered. the sensing unit PCU operates so that the rotation of perforated disc DC thereof through a light beam between light source LS and photocell PC generates a series of light pulses which, in turn, cause photocell PC to produce a corresponding number of electrical pulses or signals which are converted into square wave pulses by an electronic circuit (not shown) in unit PCU, which square wave pulses are transmitted to counter 19. When counter 19, which is presettable to receive a predetermined number of pulses and provide an output or control signal in response thereto. receives a predetermined number of such signals, it produces an output signal which is transmitted through amplifier A to operate the solenoid RS for knife clutch KC. Each such energization of solenoid RS effects one revolution of knife clutch KC and one corresponding revolution of knife bar 15 to effect cutting of one fin. One revolution of knife clutch KC also effects one operation of a reset switch RSS to effect reset of preset counter 19 to thereby place it in readiness for its next operation.

As FIG. 8 shows, counter 19 comprises a pair of power input terminals 113 and 114 to which power source P is connected. The power input terminals 113 and 114 are connected to the primary winding of a stepdown transformer T and an on-off switch SW is connected between terminal 113 and transformer T. The secondary winding of transformer T is connected to a power supply circuit which rectifies the power from transformer T and supplies it for operation of components in counter 19, in amplifier A, in sensing unit PCU, and for operation of solenoid RS. The power output terminals of counter 19 are designated 101 and 106. Counter 19 also comprises a signal input circuit IC which is connected to signal input terminal 103 which is connected to sensing unit PCU. Input circuit IC is also connected to counter circuits designated C1, C2 and C3 in counter 19. Each counter circuit C1, C2 and C3 is associated with a visual display unit designated D1, D2 and D3, respectively. Each counter circuit C1, C2 and C3 also is associated with suitable manually operable push-buttom switches PBl, PB2 and P83, respectively, shown in FIG. 2, by which the operator is able to preset counter 19 for a predetermined number of counting operations. Counter 19 also comprises a relay drive circuit RD which is connected to provide an output signal through an output terminal to amplifier A to effect energization of clutch solenoid RS.

In the embodiment hereinbefore described there is a one-to-one relationship between the rotation of the roller die RD and the rotation of knife bar 15, provided of course that the gear 63 is of an appropriate size to permit this, and the diameter of the knife bar 15 with the knife K thereon is relatively close to the diameter of the roller die RD. It is possible and advantageous to provide for cutting of a plurality of relatively short fin segments FF for each revolution of a roller die RD of a given diameter by providing an arrangement wherein, as FIG. 6A shows, a knife bar 15' is provided having four radially arranged knives K1, K2, K3 and K4 equidistantly spaced around the periphery of the knife bar and each suitably secured by cap bolts 158. This arrangement is used, as FIG. 4A shows, in conjunction with a clutch KC having a stop collar 43A which is provided with four equidistantly spaced radially arranged 9 shoulders 50a, each of which cooperates with the solenoid actuated lever 52 hereinbefore described. In the arrangement wherein the four knives are spaced 90 apart and the shoulders are spaced 90 apart, each time the solenoid RS is actuated, as hereinbefore described, the knife bar revolves only 90 to effect a cut, and it is thus possible to make four cuts providing fins FF of relatively short length (i.e., on the order, for example, of four inches) for each revolution of the roller die RD. The embodiment of the invention shown in FIGS. 4A and 6A depicts an arrangement of four knives, but it is apparent that an arrangement using two or three knives instead would also provide for cutting fin segments FF of relatively shorter length.

I claim:

1. In web processing apparatus for forming embossed or perforated segments of predetermined length from a continuous moving web of material: web feed means; rotary die means separate from said web feed means and to which said web is fed by said Web feed means and operable to provide embossments or perforations in said web; rotary cut-off means separate from said rotary die means and to which the embossed or perforated web is continuously fed by said rotary die means and operable to cut segments from the embossed or perforated end of said web while said web is moving; drive means for driving said web feed means and said rotary die means in mechanically synchronized relationship; selectively operable, electrically operated clutch means connected between said drive means and said cut-off means for intermittently operating said cutoff means from said drive means in mechanically synchronized relationship with said die means to cut said segments; and electric control means for operating said clutch means and responsive to rotation of said rotary die means to operate said clutch means and effect a single cutting operation of said cut-off means in response to a predetermined amount of rotation of said rotary die means and thereby provide an embossed or perforated segment of predetermined length and containing a predetermined number of embossments or perforations.

2. Web processing apparatus according to claim 1 wherein said electric control means includes a sensing means connected to said rotary die means and for providing electric signal information regarding the amount of rotation of said rotary die means, and electric counter means for receiving said electric signal information from said sensing means and for operating said clutch means in response thereto, and further including mechanical means for adjusting the phase relationship 10 between said sensing means and said rotary die means so that said clutch means operates said cut-off means to effect a cut at an appropriate place with respect to an embossment or perforation at an end of a segment.

3. Web processing apparatus according to claim 2 wherein said rotary die means drives a first rotatable element, wherein said sensing means comprises a sec ond rotatable element driven by said first rotatable element, and wherein said means for adjusting said phase relationship includes supporting means for adjustably mounting said sensing means in a fixed position with respect to said rotary die means wherein said first and second rotatable elements are in a desired phase relationship with respect to each other.

4. Apparatus according to claim 3 wherein said sensing means comprises photoelectric means having an interruptable beam to provide pulse signals to said counter means for effecting a single operation of said cut-off means in response to a predetermined number of said pulse signals, said counter means being selectively adjustable to change the predetermined number of pulse signals needed to effect a single operation of said cut-off means.

5. Apparatus according to claim 4 wherein said clutch means comprises a clutch and a solenoid operable in response to said counter means.

6. Apparatus according to claim 5 wherein said clutch means comprise a rotary clutch operable to effect at least a single operation of said cut-off means.

7. Apparatus according to claim 6 wherein said photoelectric sensing means comprises a light source, a photocell responsive to light from said light source, and a rotatable light interrupting means disposed between said light source and said photocell and connected to said second rotatable element.

8. Apparatus according to claim 7 wherein said first rotatable element is a first gear connected to be driven by said rotary die and said second rotatable element is a second gear.

9. Apparatus according to claim 8 wherein said supporting means for said sensing means is pivotally adjustable to selectively change the phase relationship between said first and second gears to thereby change the location at which the cut-off means cuts said web.

10. Apparatus according to claim 1 wherein said cutoff means comprises a rotary knife bar having a plurality of knife blades circumferentially arranged thereon and wherein said rotary clutch rotates less than one full revolution for each operation of said cut-off means. 

1. In web processing apparatus for forming embossed or perforated segments of predetermined length from a continuous moving web of material: web feed means; rotary die means separate from said web feed means and to which said web is fed by said web feed means and operable to provide embossments or perforations in said web; rotary cut-off means separate from said rotary die means and to which the embossed or perforated web is continuously fed by said rotary die means and operable to cut segments from the embossed or perforated end of said web while said web is moving; drive means for driving said web feed means and said rotary die means in mechanically synchronized relationship; selectively operable, electrically operated clutch means connected between said drive means and said cut-off means for intermittently operating said cut-off means from said drive means in mechanically synchronized relationship with said die means to cut said segments; and electric control means for operating said clutch means and responsive to rotation of said rotary die means To operate said clutch means and effect a single cutting operation of said cut-off means in response to a predetermined amount of rotation of said rotary die means and thereby provide an embossed or perforated segment of predetermined length and containing a predetermined number of embossments or perforations.
 2. Web processing apparatus according to claim 1 wherein said electric control means includes a sensing means connected to said rotary die means and for providing electric signal information regarding the amount of rotation of said rotary die means, and electric counter means for receiving said electric signal information from said sensing means and for operating said clutch means in response thereto, and further including mechanical means for adjusting the phase relationship between said sensing means and said rotary die means so that said clutch means operates said cut-off means to effect a cut at an appropriate place with respect to an embossment or perforation at an end of a segment.
 3. Web processing apparatus according to claim 2 wherein said rotary die means drives a first rotatable element, wherein said sensing means comprises a second rotatable element driven by said first rotatable element, and wherein said means for adjusting said phase relationship includes supporting means for adjustably mounting said sensing means in a fixed position with respect to said rotary die means wherein said first and second rotatable elements are in a desired phase relationship with respect to each other.
 4. Apparatus according to claim 3 wherein said sensing means comprises photoelectric means having an interruptable beam to provide pulse signals to said counter means for effecting a single operation of said cut-off means in response to a predetermined number of said pulse signals, said counter means being selectively adjustable to change the predetermined number of pulse signals needed to effect a single operation of said cut-off means.
 5. Apparatus according to claim 4 wherein said clutch means comprises a clutch and a solenoid operable in response to said counter means.
 6. Apparatus according to claim 5 wherein said clutch means comprise a rotary clutch operable to effect at least a single operation of said cut-off means.
 7. Apparatus according to claim 6 wherein said photoelectric sensing means comprises a light source, a photocell responsive to light from said light source, and a rotatable light interrupting means disposed between said light source and said photocell and connected to said second rotatable element.
 8. Apparatus according to claim 7 wherein said first rotatable element is a first gear connected to be driven by said rotary die and said second rotatable element is a second gear.
 9. Apparatus according to claim 8 wherein said supporting means for said sensing means is pivotally adjustable to selectively change the phase relationship between said first and second gears to thereby change the location at which the cut-off means cuts said web.
 10. Apparatus according to claim 1 wherein said cut-off means comprises a rotary knife bar having a plurality of knife blades circumferentially arranged thereon and wherein said rotary clutch rotates less than one full revolution for each operation of said cut-off means. 